US20220118664A1 - Injection molding apparatus - Google Patents
Injection molding apparatus Download PDFInfo
- Publication number
- US20220118664A1 US20220118664A1 US17/244,613 US202117244613A US2022118664A1 US 20220118664 A1 US20220118664 A1 US 20220118664A1 US 202117244613 A US202117244613 A US 202117244613A US 2022118664 A1 US2022118664 A1 US 2022118664A1
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- United States
- Prior art keywords
- molten material
- conduit device
- manifold
- material conduit
- back plate
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
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- 238000001746 injection moulding Methods 0.000 title claims abstract description 97
- 239000012768 molten material Substances 0.000 claims abstract description 426
- 238000002347 injection Methods 0.000 claims abstract description 54
- 239000007924 injection Substances 0.000 claims abstract description 54
- 239000012636 effector Substances 0.000 claims abstract description 45
- 230000000694 effects Effects 0.000 claims description 33
- 238000004891 communication Methods 0.000 claims description 16
- 238000006073 displacement reaction Methods 0.000 claims description 6
- 230000004044 response Effects 0.000 claims description 6
- 239000011797 cavity material Substances 0.000 claims 8
- 238000007789 sealing Methods 0.000 abstract description 3
- 230000013011 mating Effects 0.000 description 5
- 230000004941 influx Effects 0.000 description 3
- 230000006978 adaptation Effects 0.000 description 1
- 230000002411 adverse Effects 0.000 description 1
- 238000000429 assembly Methods 0.000 description 1
- 230000000712 assembly Effects 0.000 description 1
- 230000008901 benefit Effects 0.000 description 1
- 230000005540 biological transmission Effects 0.000 description 1
- 230000001351 cycling effect Effects 0.000 description 1
- 230000008595 infiltration Effects 0.000 description 1
- 238000001764 infiltration Methods 0.000 description 1
- 238000009434 installation Methods 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 238000000465 moulding Methods 0.000 description 1
- 230000008439 repair process Effects 0.000 description 1
- 230000000087 stabilizing effect Effects 0.000 description 1
Images
Classifications
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
- B29C45/17—Component parts, details or accessories; Auxiliary operations
- B29C45/26—Moulds
- B29C45/27—Sprue channels ; Runner channels or runner nozzles
- B29C45/2725—Manifolds
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
- B29C45/17—Component parts, details or accessories; Auxiliary operations
- B29C45/20—Injection nozzles
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
- B29C45/17—Component parts, details or accessories; Auxiliary operations
- B29C45/26—Moulds
- B29C45/27—Sprue channels ; Runner channels or runner nozzles
- B29C45/2725—Manifolds
- B29C2045/2733—Inserts, plugs, bushings
Definitions
- the present disclosure relates generally to an injection molding apparatus for use in an injection molding machine.
- the present disclosure relates to an injection molding apparatus for receiving molten material from an injection nozzle of an injection molding machine and for delivering the molten material to a mold cavity of the injection molding apparatus.
- Injection molding machines typically include a conduit device, such as a sprue bar, mounted within a corresponding opening formed within a portion of the mold assembly for delivering molten material to the corresponding mold cavity or mold cavities of the injection molding machine.
- the sprue bar often extends through corresponding openings formed in the one or more mold plates that make up the mold assembly.
- the sprue bar is arranged within the mold assembly such that one end of the sprue bar communicates with a manifold structure, which in some instances includes a manifold insert disposed within a manifold plate, for delivering molten material to the one or more mold cavities housed within the mold.
- the other end of the sprue bar which is arranged or exposed on the exterior of the mold assembly, communicates with the injection molding machine nozzle for receiving the molten material from the injection molding machine nozzle.
- a common challenge of injection molds is the difficulty to achieve and maintain alignment of the sprue bar, or other conduit device, with the manifold or manifold insert of the combined manifold insert and manifold plate. Alignment of the sprue bar with the injection nozzle can also present challenges. Misalignment of the sprue bar, or conduit device, results in misalignment of the opening of the sprue bar that communicates with the opening on the manifold that receives the molten material. This misalignment often results in leakage of the molten material within other parts of the mold assembly as well as improper and/or incomplete injection of molten material into the mold.
- Leakage of molten material outside of the mold cavity and within the mold assembly can result in damage to the overall mold assembly that requires a shutdown of the molding operation to clean, repair and/or replace the mold assembly or components within the mold assembly, and may also result in improperly formed molded products.
- an injection molding apparatus for receiving molten material from an injection machine nozzle of an injection molding machine, and delivering the molten material to at least one mold cavity housed within a cavity side of a mold assembly
- the injection molding apparatus comprising a manifold, wherein the manifold comprises a manifold plate, and a manifold insert disposed within the manifold plate, the manifold insert including a molten material receiver configured for receiving molten material, and at least one passageway for transmitting the molten material received at the molten material receiver to the at least one mold cavity; a molten material conduit device having an inlet opening for receiving the molten material from the injection machine nozzle, a discharge opening for transmitting the molten material to the molten material receiver, and a molten material conduit extending therebetween; and a back plate disposed on the manifold plate and configured for cooperating with the injection machine nozzle; wherein: the molten material conduit device includes a base
- An injection molding apparatus for receiving molten material from an injection machine nozzle of an injection molding machine, and delivering the molten material to at least one mold cavity housed within a cavity side of a mold assembly, comprising: a manifold insert defining a molten material receiver and at least one passageway; a manifold plate configured for receiving the manifold insert; a molten material conduit device having an inlet opening for receiving the molten material from the injection machine nozzle, a discharge opening for transmitting the molten material to the molten material receiver, and a molten material conduit extending therebetween; and a back plate having a molten material conduit device engaging flange defining a molten material conduit device receiving opening, the back plate configured for disposition on the manifold plate and for cooperating with the injection machine nozzle; wherein: the molten material conduit device includes a base flange extending outwardly from the discharge opening, the base flange defining: a manifold insert sealed interface effector; and an aligner;
- FIG. 1 is a cross-sectional view through an injection molding apparatus according to an example embodiment of the present disclosure with an injection nozzle disposed for delivering molten material to the apparatus;
- FIG. 1A is another cross-sectional view of the injection molding apparatus, taken 90 degrees relative to the cross-sectional view of FIG. 1 , with the injection nozzle removed and illustrating a manifold passageway;
- FIG. 2 is a detail cross-sectional side view of a molten material conduit device mounted within the injection molding apparatus, as shown in FIGS. 1 and 1A ;
- FIG. 3 is a bottom perspective view of the base of the molten material conduit device according to an example embodiment of the present disclosure
- FIG. 4 is a perspective top view of the molten material conduit device
- FIG. 5 is a bottom, perspective view of the molten material conduit device with mounting screws in place
- FIG. 6 is a top plan view of the injection molding apparatus of FIGS. 1-1A illustrating the injection nozzle seat provided by the molten material conduit device;
- FIG. 7 is a cross sectional view through the injection molding apparatus illustrating the communication between the molten material conduit device and a mold cavity via the manifold;
- FIG. 8 is a perspective, cross-sectional view of the injection molding apparatus illustrating the mounting of the molten material conduit device relative to the manifold.
- the injection molding apparatus 100 is configured for delivering molten material from an injection machine nozzle 110 of an injection molding machine to a mold cavity 112 that is formed within the cavity side 103 of a mold assembly 102 of the injection molding apparatus 100 .
- the cavity side 103 of the mold assembly 102 includes a plurality of mold cavities 112 , the injection machine nozzle 110 delivering molten material to the plurality of mold cavities 112 housed within the cavity side 103 of the mold assembly 102 via a network of passageways formed within the injection molding apparatus 100 .
- the manifold insert 114 A is configured for delivering molten material to the one or more mold cavities 112 housed within the cavity side 103 of the mold assembly, while the manifold plate 114 b is configured for supporting the manifold insert 114 A and stationing the manifold insert 114 A in position relative to the mold assembly. Accordingly, in such embodiments, the manifold insert 114 A together with the manifold plate 114 B make-up the manifold 114 with the manifold insert 114 A defining the network of passageways formed within the injection molding apparatus 100 for delivering the molten material, received from the injection machine nozzle 110 , to the one or more mold cavities 112 . It will be understood, however, that in some example embodiments, the manifold 114 may have different configurations and that the manifold 114 is not necessarily limited to a configuration including a manifold insert disposed within a corresponding manifold plate.
- the manifold plate 114 B is configured to receive the manifold insert 114 A.
- the manifold plate 114 B includes a receiving cavity 1114 configured for receiving the manifold insert 114 A.
- the manifold insert 114 A includes at least one passageway 118 for distributing the molten material received from the injection machine nozzle 110 to the one or more mold cavities 112 .
- the manifold insert 114 A is installed within the receiving cavity 1114 of the manifold plate 114 B. Accordingly, molten material delivered to the manifold insert 114 A is transmitted through the manifold insert 114 A, to the cavity side 103 of the mold assembly 102 .
- the manifold insert 114 A communicates with an inlet on the cavity side 103 of the mold assembly 102 , when the injection molding apparatus 100 is in a closed condition, for transmitting the molten material to the cavity side 103 of the mold assembly. Therefore, the manifold insert 114 A is installed within the manifold plate 114 B, such that while the injection molding apparatus 100 is in a closed condition and molten material is supplied to the apparatus 100 by the injection machine nozzle 110 , molten material received at the manifold insert 114 A travels through the manifold insert 114 A, housed within and supported by the manifold plate 114 B, to the one or more mold cavities 112 .
- the manifold 114 serves to receive molten material from the injection machine nozzle 110 and distribute the molten material to the one or more mold cavities 112 housed within the cavity side 103 of the mold assembly 102 of the injection molding apparatus 100 through a manifold insert 114 A disposed within and supported by a manifold plate 114 b, or any other suitable configuration.
- the second side 115 of the manifold plate 114 B which is disposed opposite to the first side 113 , serves as the molten material-receiving side of the manifold 114 and is configured for mating contact with and being secured to a back plate 120 that encloses or seals the molten material-receiving side of the manifold 114 .
- the manifold insert 114 A includes a molten material receiver, or inlet, 116 that is configured for receiving a supply of molten material that is delivered to the injection molding apparatus 100 via the injection machine nozzle 110 .
- the molten material receiver 116 communicates with the at least one passageway 118 that extends through the manifold insert 114 A, from the molten material receiver 116 , which communicates with a corresponding inlet on the cavity side 103 of the mold assembly 102 for establishing communication between the manifold insert 114 A and the cavity side 103 of the mold assembly 102 .
- the at least one passageway 118 defined in the manifold insert 114 A is part of a network of passageways 1118 that are interconnected for distributing the molten material received at the molten material receiver 116 through the manifold insert 114 A to the one or more mold cavities 112 housed within the cavity side 103 of the mold assembly 102 .
- the back plate 120 is configured for mounting on and being secured to the second, molten material-receiving side 115 of the manifold plate 114 b.
- the back plate 120 has a manifold engaging side 122 that is configured for mating contact with the second side 115 of the manifold plate 114 b such that a sealed interface is effected therebetween.
- the back plate 120 also has a machine nozzle engaging side 124 that is disposed opposite to the manifold engaging side 122 , wherein the machine nozzle engaging side 124 is configured for engaging the injection machine nozzle 110 of the injection molding apparatus 100 so that the injection machine nozzle 110 can deliver molten material to the injection molding apparatus 100 .
- the injection molding apparatus 100 in order to effect transmission of the molten material from the injection machine nozzle 110 to the manifold insert 114 A, the injection molding apparatus 100 includes a molten material conduit device 130 .
- the molten material conduit device 130 is configured for engaging with the injection machine nozzle 110 for receiving the molten material from the injection machine nozzle 110 , and for delivering the supply of molten material received from the injection machine nozzle 110 to the at least one passageway 118 (or network of passageways 1118 ) in the manifold insert 114 A, via communication with the molten material receiver 116 .
- the molten material conduit device 130 has an inlet end 132 that defines an inlet opening 134 , for engaging with the injection machine nozzle 110 , and discharge end 136 defining a discharge opening 138 for delivering the supply of molten material received at the inlet opening 134 to the molten material receiver 116 .
- a molten material conduit 140 extends between and interconnects the inlet opening 134 and the discharge opening 138 .
- the molten material conduit device 130 is configured for disposition on the manifold insert 114 A such that the discharge end 136 is disposed in abutting contact with the manifold insert 114 A with effect that the that the discharge opening 138 of the molten material conduit device 130 is aligned with and disposed in communication with the molten material receiver 116 .
- the molten material conduit device 130 extends through the back plate 120 such that the inlet end 132 and inlet opening 134 remain exposed and accessible from the machine nozzle engaging side 124 of the back plate 120 for engagement with the injection machine nozzle 110 .
- the molten material conduit device 130 may vary in length depending on the particular application and/or overall design of the back plate 120 and/or the injection molding apparatus 100 .
- the molten material conduit device 130 is a sprue bar.
- the injection molding apparatus 100 includes a locating ring 300 for supporting the inlet end 132 of the molten material conduit device 130 in position relative to the machine nozzle engaging side 124 of the back plate 120 .
- the locating ring 300 also serves to locate the inlet end 132 and the inlet opening 134 relative to the machine nozzle-engaging side 124 of the back plate 120 to facilitate proper alignment of the injection machine nozzle 110 with the inlet opening 134 of the molten material conduit device 130 .
- the locating ring 300 includes a central opening 301 for receiving the inlet end 132 of the molten material conduit device 130 .
- the inlet end 132 of the molten material conduit device 130 is received within the central opening 301 of the locating ring 300 such that a sealed interface 303 is effected between the locating ring 300 and the inlet end 132 of the molten material conduit device 130 such that the molten material discharged from the injection machine nozzle 110 is directed solely through the inlet opening 134 and molten material conduit 140 of the molten material conduit device 130 .
- the sealed interface 303 between the inlet end 132 of the molten material conduit device 130 and the corresponding edge surface defined by the central opening 301 in the locating ring 300 serves to prevent molten material from seeping between the molten material conduit device 130 and the back plate 120 into the manifold 114 or manifold insert 114 A.
- the locating ring 300 has a sloping or concave surface 302 that extends around the central opening 301 for providing sufficient clearance to allow for proper engagement of the injection machine nozzle 110 against the inlet end 132 and inlet opening 134 of the molten material conduit device 130 .
- the injection machine nozzle 110 is moved into engagement with the inlet end 132 of the molten material conduit device 130 for delivering a supply of molten material to the injection molding apparatus 100 via the inlet opening 134 .
- the injection machine nozzle 110 is moved out of engagement with the inlet end 132 of the molten material conduit device 130 and the molten material is allowed to cure within the mold cavities to form the molded article(s).
- the injection molding apparatus 100 is opened and the molded article(s) ejected or otherwise removed from the mold assembly 102 and the injection molding cycle can continue.
- Misalignment of the sprue bar (or other molten material conduit device) relative to the manifold (or manifold insert) may occur due to the repeated cycling of the injection machine nozzle being brought into contact with the inlet end of the sprue bar (or other molten material conduit device), which in some instances, may result in dislodging or displacement of the sprue bar (or other molten material conduit device) relative to the manifold or manifold insert.
- the mounting of the sprue bar relative to the manifold is such that the sprue bar is prone to rotation about an axis that extends normal to the injection axis in response to the forces applied to the sprue bar by the repeated engagement of the injection machine nozzle with the injection molding apparatus against the inlet end of the sprue bar.
- any displacement, or rotation, of the sprue bar relative to the manifold (or manifold insert) can result in the sprue bar separating from the manifold or manifold insert and/or misalignment of the sprue bar relative to the inlet to the manifold (or manifold insert) which may lead to unwanted leakage of molten material within with manifold or mold assembly thereby damaging the mold.
- the molten material conduit device 130 is configured for secure mounting relative to the manifold insert 114 A within the injection molding apparatus 100 in an effort to maintain proper alignment of the molten material conduit device 130 relative to the manifold insert 114 A over repeated operating cycles of the injection molding apparatus 100 to reduce the likelihood of leakage of molten material within the injection molding apparatus 100 and mitigate the potential damage cause by any leakage that may occur.
- the molten material conduit device 130 is disposed relative to the manifold 114 such that the discharge end 136 of the molten material conduit device 130 is disposed in abutting contact with the manifold insert 114 A.
- Disposition of the discharge end 136 of the molten material conduit device 130 in abutting contact with the manifold insert 114 A is with effect that the discharge opening 138 of the molten material conduit device 130 is aligned with and disposed in communication with the molten material receiver 116 formed in the manifold insert 114 A.
- the discharge end 136 of the molten material conduit device 130 is also configured for effecting a sealed interface between the molten material conduit device 130 and the manifold 114 , or manifold insert 114 A.
- the base flange 160 extends radially outwardly from the discharge opening 138 defined by the molten material conduit device 130 such that the manifold insert sealed interface effector 142 defines an annular area wherein the annular area has an inner radius, R 1 , as measured from the central axis of the discharge opening 138 to the circumference of the discharge opening 138 (which corresponds to the radius of the discharge opening 138 ), and an outer radius, R 2 , as measured from the central axis of the discharge opening 138 , along the first side or bottom surface 161 of the base flange 160 to an outer edge 163 of the base flange 160 defined by the discharge end 136 of the molten material conduit device 130 .
- the inner radius, R 1 is between a minimum of 6.35 mm to a maximum of 25.4 mm.
- the outer radius, R 2 is between a minimum of 38.1 mm to maximum of 57.15 mm.
- molten material conduit device engagers 196 are employed for engaging the discharge end 136 of the molten material conduit device 130 and locating the molten material conduit device 130 relative to the manifold insert 114 A while the molten material conduit device 130 is mounted on the manifold insert 114 A.
- the molten material conduit device engagers 196 have a first end 197 configured for engaging the manifold insert 114 A and a second, opposite end 198 configured for engaging the bottom surface or first side 161 of the base flange 160 .
- the manifold insert 114 A includes one or more engager-receivers, or openings, 200 configured for receiving the corresponding first end 197 of the molten material conduit device engagers 196 .
- the base flange 160 of the discharge end 136 includes one or more engager-receivers (or openings) 202 configured for receiving the corresponding second end 198 of a respective one of the molten material conduit device engagers 196 .
- the mating engagement between the molten material conduit device engagers 196 with both the manifold insert 114 A and the discharge end, or base flange 160 , of the molten material conduit device 130 serves to locate the molten material conduit device 130 relative to the manifold insert 114 A and hold the molten material conduit device 130 in position relative to the manifold insert 114 A during assembly of the injection molding apparatus 100 .
- the molten material conduit device-engagers 196 are dowel pins.
- the back plate 120 is disposed on the manifold plate 114 b, with at least a portion of the molten material conduit device 130 extending therethrough, for enclosing and sealing against the second, molten material-receiving side 115 of the manifold plate 114 b.
- the discharge end 136 of the molten material conduit device 130 is configured for engaging with the back plate 120 such that at least a portion of the base flange 160 is disposed intermediate, or is pinched between, the manifold insert 114 A and the back plate 120 .
- the discharge end 136 of the molten material conduit device 130 includes a back-plate engager 144 that is configured for engagement between the manifold insert 114 A and the back plate 120 such that a second sealed interface 153 is effected between at least a portion of the second side 162 of the base flange 160 and the manifold engaging side 122 of the back plate 120 .
- the back plate-engager 144 includes at least a portion of the base flange 160 .
- the back plate 120 includes a molten material conduit device engaging flange 152 that defines a molten material conduit device-receiving opening 150 .
- the molten material conduit device engaging flange 152 is configured such that as the back plate 120 is mounted on the manifold 114 and disposed in abutting contact with the manifold plate 114 b, the molten material conduit device 130 extends through the molten material conduit device-receiving opening 150 .
- the molten material conduit device 130 and the molten material conduit device-engaging flange 152 are cooperatively configured such that, while the molten material conduit device 130 is mounted on the manifold insert 114 A in communication with the molten material receiver 116 and the back plate 120 is mounted on the manifold plate 114 b, the molten material conduit device-engaging flange 152 engages with and is disposed in abutting contact with the back plate engager 144 .
- disposition of the back plate 120 in abutting contact with the manifold plate 114 b, and the discharge end 136 of the molten material conduit device 130 is with effect that pressure is applied to the back plate engager 114 due to the “pinching” of the back plate engager 144 between the molten material conduit device-engaging flange 152 defined by the back plate 120 and the manifold insert 114 A.
- the pressure applied to the back plate engager 144 by the back plate 120 , contributes to the establishment of the first sealed interface 142 A between the manifold insert sealed interface effector 142 and the manifold insert 114 A.
- the pressure applied to the back plate engager 144 , by the back plate 120 also contributes to the establishment of the second sealed interface 153 between the back plate sealed interface effector 164 defined by the discharge end 136 of the molten material conduit device 130 and the molten material conduit device-engaging flange 152 of the back plate 120 .
- Establishment of the second sealed interface 153 between the back plate sealed interface effector 162 defined by the back plate engager 144 of the discharge end 136 of the molten material conduit device 130 and the corresponding surface defined by the molten material conduit device-engaging flange 152 of the back plate 120 is with effect that, should leakage of molten material exterior to the molten material conduit device 130 occur (for instance if leakage of molten material occurs between the inlet end 132 of the molten material conduit device 130 and the locating ring 300 ), further infiltration of this molten material into the injection molding apparatus 100 between the back plate 120 and the manifold plate 114 b is resisted.
- the discharge end 136 of the molten material conduit device 130 includes a relief passage 170 that extends through the discharge end 136 of the molten material conduit device 130 for directing molten material away from the sealed interface 142 A established between the discharge end 136 of the molten material conduit device 130 and the manifold insert 114 A towards the machine nozzle-engaging side 124 of the back plate 120 (or the back side of the injection molding apparatus 100 ).
- the relief passage 170 is configured such that, in the event that leakage of molten material from the discharge opening 138 of the molten material conduit device 130 between the manifold insert sealed interface effector 142 defined by the base flange 160 and the corresponding surface of the manifold insert 114 A occurs with effect that the sealed interface 142 A established by the abutting contact between the manifold insert sealed interface effector 142 and the manifold insert 114 A is defeated, the leaking molten material is directed through the relief passage 170 , towards the second, or machine nozzle-engaging side 124 of the back plate 120 (or back side of the injection molding apparatus 100 ).
- the leaking molten material is directed away from the manifold insert 114 A and any passageways that are contained within the manifold insert 114 A that are not intended for the influx of molten material.
- Directing the leaking molten material away from the manifold insert 114 A and away from any passageways contained within the manifold insert 114 A or manifold plate 114 b that are not intended for the influx of molten material also helps to direct any leakage of molten material away from auxiliary equipment and any related wiring, for example heaters, contained within the manifold insert 114 A, or within any other parts of the mold assembly 102 or injection molding apparatus 100 with helps to mitigate overall damage to the mold assembly 102 or injection molding apparatus 100 .
- disposition of the back plate 120 on the manifold plate 114 b with the molten material conduit device 130 extending through the molten material conduit device-receiving opening 150 such that the back plate engager 144 is pinched between the manifold insert 114 A and the back plate 120 is also with effect that the discharge opening 138 of the molten material conduit device 130 is aligned with the molten material receiver 116 .
- Alignment of the discharge opening 138 with the molten material receiver 116 establishes communication between the inlet opening 134 of the molten material conduit device 130 with the molten material receiver 116 such that, when a supply of molten material is delivered to the inlet opening 134 , the molten material is directed to the molten material receiver 116 by way of the molten material conduit 140 and the discharge opening 138 of the molten material conduit device 130 .
- the relief passage 170 includes a groove 172 disposed within the first side 161 or manifold insert sealed interface effector 142 of the base flange 160 of the molten material conduit device 130 , the groove 172 extending around the discharge opening 138 .
- the groove 172 extends into, or is recessed into, the bottom surface 161 , or the manifold insert sealed interface effector 142 , defined by the base flange 160 such that, when the molten material conduit device 130 is disposed in mating contact with the manifold insert 114 A, there is an absence of contact between the bottom surface 161 of the discharge end 136 and the manifold insert 114 A in the region defined by the groove 172 .
- a plurality of relief openings 174 are disposed at spaced apart intervals about the groove 172 , the plurality of relief openings 174 extending through the discharge end 136 of the molten material conduit device 130 from the recessed area defined by the groove 172 to the back (or rear surface) or second side 162 of the discharge end 136 .
- the plurality of relief openings 174 are disposed about the groove 172 such that, while the molten material conduit device 130 is mounted on the manifold insert 114 A and the back plate 120 is mounted on the manifold plate 114 b, each of the plurality of relief openings 174 is unobstructed by, or remains free from interference from, the molten conduit device engaging flange 152 defined by the back plate 120 .
- the groove 172 and the plurality of relief openings 174 are cooperatively configured such that, while the molten material conduit device 130 is mounted on the manifold insert 114 A, the groove 172 faces the manifold insert 114 A such that any leakage of molten material between the manifold insert sealed interface effector 142 defined by the base flange 160 and the manifold insert 114 A will enter or flow into the recessed area defined by the groove 172 . Molten material entering the groove 172 will travel around the groove 172 until the molten material reaches one or more of the plurality relief openings 174 disposed in communication with the groove 172 .
- the molten material passes through the one or more relief openings 174 and out through the second or rear side 162 of the discharge end 136 of the molten material conduit device 130 towards the exterior of the injection molding apparatus 100 . Accordingly, molten material that enters the groove 172 and that travels through the one or more of the plurality of relief openings 174 is directed away from the remaining portion of the sealed interface 142 a that is effected between the manifold insert sealed interface effector 142 and the manifold insert 114 A thereby maintaining at least a portion of the sealed interface 142 A between the discharge end 136 and the manifold insert 114 .
- the sealed interface 142 A remains effective in the event that there is some leakage of molten material from the discharge opening 138 between the discharge end 136 of the molten material conduit device 130 and the manifold insert 114 A and diverting any leakage of molten material away from critical areas of the manifold insert 114 A, the potential damage due to unwanted influx of molten material into critical areas of the manifold insert is reduced.
- the injection molding apparatus 100 includes a back plate relief passage 190 for directing any leakage of molten material to the exterior of the injection molding apparatus 100 .
- the back plate-relief passage 190 extends within the back plate 120 and is open to the region surrounding the molten material conduit device 130 into which the plurality of relief openings 174 discharge. Accordingly, any leakage of molten material within the apparatus 100 that is diverted away from the sealed interface 142 A through the groove 172 and the plurality of relief openings 174 into the region surrounding the molten material conduit device 130 will be easily identified by operators of the injection molding apparatus 100 once the molten material escapes through the back plate relief passage 190 . Early identification of leakage of molten material within the injection molding apparatus 100 can serve to mitigate and/or reduce the overall damage to the manifold insert 114 A and/or other critical components of the injection molding apparatus 100 caused by the leakage of molten material.
- the molten material conduit device 130 further includes an aligner 180 for effecting alignment of the discharge opening 138 of the molten material conduit device 130 with the molten material receiver 116 during assembly of the injection molding apparatus 100 .
- the aligner 180 is configured for cooperating with the molten material conduit device-engaging flange 152 that is defined by the back plate 120 .
- the aligner 180 cooperates with the molten material conduit device-engaging flange 152 such that, while the molten material conduit device 130 is disposed on the manifold insert 114 A and the back plate 120 is disposed on the manifold plate 114 b, an edge surface 156 of the molten material conduit device-engaging flange 152 is disposed in abutting contact engagement with an edge surface 182 of the aligner 180 .
- the radius, R 2 , of the base flange 160 is greater than the radius, RA, defined by the aligner 180 such that the portion of the base flange 160 that extends beyond the aligner 180 and defines the back plate engager 144 has sufficient surface area to be sandwiched or pinched between the manifold 114 and the back plate 120 and define a sealed interface between the back plate sealed interface effector 164 and the corresponding surface of the back plate 120 .
- the radius, RA, of the aligner 180 is selected such that it is between a minimum of at least 31.75 mm to a maximum of 50.8 mm.
- the molten material conduit device 130 is configured such that the ratio of the outer radius, R 2 , of the base flange 160 to the radius, RA, of the aligner 180 is anywhere between at least 1:1.1 and 1:1.2.
- disposition of the back plate 120 on the manifold plate 114 b such that the molten material conduit device-engaging flange 152 is disposed in abutting contact with the back plate-sealed interface effector 164 defined by the back plate engager 144 such that the edge surface 156 of the molten material conduit device-engaging flange 152 is disposed in abutting contact with the corresponding edge surface 182 of the aligner 130 is with effect that rotation of the molten material conduit device 130 relative to the manifold insert 114 A about an axis that extends normal to the central longitudinal axis 133 of the molten material conduit 140 of the molten material conduit device 130 (or the injection axis of the injection machine nozzle 110 ) is resisted due to the interference between the discharge end 136 of the molten material conduit device 130 and the molten material conduit device-engaging flange 152 .
- rotation of the molten material conduit device 130 relative to the manifold insert 114 A about an axis that extends normal to the central longitudinal axis 133 of the molten material conduit 140 of the molten material conduit device 130 is resisted due to the interference between the back plate engager 144 and the molten material conduit device engaging flange 152 as well as due to interference between the aligner 180 and the back plate 120 , specifically, the edge surface 182 of the aligner 180 impinging against the corresponding edge surface 156 defines by the molten material conduit device engaging flange 152 .
- the manifold insert 114 A includes corresponding fastener openings 206 that cooperate with the fasteners 208 such that when the molten material conduit device 130 is disposed on the manifold insert 114 A, the fastener openings 204 on the molten material conduit device 130 align with the fastener openings 206 on the manifold insert 114 A and the corresponding fasteners 208 extend through the aligned fastener openings 204 , 206 securing the molten material conduit device 130 to the manifold 114 .
- the fastener openings 204 , 206 are threaded openings for cooperating with corresponding threaded fasteners 208 .
- the molten material conduit device 130 is also secured in position relative to the manifold insert 114 A and back plate 120 by means of the disposition of the back plate engager 144 between the manifold insert 114 A and the molten material conduit device engaging flange 152 , and the abutting contact between the edge surface 182 of the aligner 180 and the corresponding edge surface 156 of the molten material conduit device engaging flange 152 , the amount of force exerted by the fasteners 208 to secure the molten material conduit device 130 to the manifold insert 114 A is minimized.
- Minimizing the amount of force exerted by fasteners 208 on the discharge end 136 of the molten material conduit device 130 reduces the risk of an imbalance of forces being applied to the base flange 160 that could have an adverse effect of the establishment of the sealed interface 142 A between the manifold insert sealed interface effector 142 and the manifold insert 114 A.
- fasteners 208 are not required where the clamping effect of the back plate 120 against the discharged end 136 of the molten material conduit device 130 is sufficient to ensure stability of the molten material conduit device 130 relative to the manifold insert 114 A.
- back plate fasteners 220 are used that are configured to extend through corresponding fastener-receiving openings 224 , 226 disposed in the back plate 120 and in the manifold plate 114 b.
- the securing of the back plate 120 to the manifold plate 114 b via the back plate fasteners 220 fixes the back plate 120 to the manifold plate 114 b effectively clamping the back plate 120 to the manifold plate 114 b.
- the clamping together of the back plate 120 and the manifold plate 114 b, by way of the back plate fasteners 220 , is with effect that some of the clamping effect is transmitted to the molten material conduit device 130 via the molten material conduit device-engaging flange 152 for securing and stabilizing the molten material conduit device 130 in position relative to the manifold insert 114 A and within the injection molding apparatus 100 .
- the back plate fasteners 220 and the corresponding openings 224 , 226 are spaced apart from the central longitudinal axis 131 of the molten material conduit device 130 by a radial distance, D, that is about five times greater than the radial distance, d, by which the molten material conduit device fasteners 208 are spaced relative to the central longitudinal axis 131 of the central longitudinal axis 131 .
- Stress that may be induced on the base flange 160 as a result of the fasteners 220 being secured within the corresponding openings 224 , 226 can result in an imbalance of forces applied to the discharge end 136 or base flange 160 of the molten material conduit device 130 that can lead to misalignment of the discharge opening 138 with the molten material receiver 116 .
- the fasteners 220 can be installed at a greater distance away from the location of the molten material conduit device 130 which facilitates assembly of the injection molding apparatus 100 since the potential for the creation of imbalanced forces on the molten material conduit device 130 , as torque is applied to the fasteners 220 , is reduced as a result of the positioning of the fasteners 220 relative to the molten material conduit device 130 within the injection molding apparatus 100 .
- the force imparted by each of the back plate fasteners 220 is about 40700 lb while the force imparted by each of the molten material conduit device fasteners 208 is about 9960 lb.
Abstract
An injection molding apparatus for receiving molten material from an injection nozzle and delivering the molten material to a mold cavity is disclosed. The injection molding apparatus includes a molten material conduit device for receiving the molten material and directing the molten material to a molten material receiver defined by a manifold, the manifold directing the molten material the mold cavity housed within the mold assembly of the apparatus. The molten material conduit device includes a manifold-sealed interface effector for sealing against the manifold, and a back plate engager for engaging the back plate that secures the molten material conduit device to the manifold. The manifold, the molten material conduit device and the back plate are cooperatively configured such that a discharge end of the conduit device is sandwiched between the manifold and the back plate and such that the discharge opening is disposed in alignment with the molten material-receiver.
Description
- This application claims the benefit of and priority to U.S. Provisional Patent Application No. 63/094,090 filed Oct. 20, 2020 under the title INJECTION MOLDING APPARATUS, the content of which is hereby expressly incorporated by reference into the detailed description hereof.
- The present disclosure relates generally to an injection molding apparatus for use in an injection molding machine. In particular, the present disclosure relates to an injection molding apparatus for receiving molten material from an injection nozzle of an injection molding machine and for delivering the molten material to a mold cavity of the injection molding apparatus.
- Injection molding machines typically include a conduit device, such as a sprue bar, mounted within a corresponding opening formed within a portion of the mold assembly for delivering molten material to the corresponding mold cavity or mold cavities of the injection molding machine. The sprue bar often extends through corresponding openings formed in the one or more mold plates that make up the mold assembly. In some instances, the sprue bar is arranged within the mold assembly such that one end of the sprue bar communicates with a manifold structure, which in some instances includes a manifold insert disposed within a manifold plate, for delivering molten material to the one or more mold cavities housed within the mold. The other end of the sprue bar, which is arranged or exposed on the exterior of the mold assembly, communicates with the injection molding machine nozzle for receiving the molten material from the injection molding machine nozzle.
- A common challenge of injection molds is the difficulty to achieve and maintain alignment of the sprue bar, or other conduit device, with the manifold or manifold insert of the combined manifold insert and manifold plate. Alignment of the sprue bar with the injection nozzle can also present challenges. Misalignment of the sprue bar, or conduit device, results in misalignment of the opening of the sprue bar that communicates with the opening on the manifold that receives the molten material. This misalignment often results in leakage of the molten material within other parts of the mold assembly as well as improper and/or incomplete injection of molten material into the mold. Leakage of molten material outside of the mold cavity and within the mold assembly can result in damage to the overall mold assembly that requires a shutdown of the molding operation to clean, repair and/or replace the mold assembly or components within the mold assembly, and may also result in improperly formed molded products.
- Accordingly, injection mold assemblies that offer improved sprue bar or conduit alignment and effective sealing of the sprue bar within the mold assembly in an effort to reduce, or mitigate, the effects of leakage of molten material within the mold assembly are desirable.
- In accordance with an aspect of the present disclosure there is provided an injection molding apparatus for receiving molten material from an injection machine nozzle of an injection molding machine, and delivering the molten material to at least one mold cavity housed within a cavity side of a mold assembly, the injection molding apparatus comprising a manifold, wherein the manifold comprises a manifold plate, and a manifold insert disposed within the manifold plate, the manifold insert including a molten material receiver configured for receiving molten material, and at least one passageway for transmitting the molten material received at the molten material receiver to the at least one mold cavity; a molten material conduit device having an inlet opening for receiving the molten material from the injection machine nozzle, a discharge opening for transmitting the molten material to the molten material receiver, and a molten material conduit extending therebetween; and a back plate disposed on the manifold plate and configured for cooperating with the injection machine nozzle; wherein: the molten material conduit device includes a base flange extending outwardly from the discharge opening, the base flange having a first side defining a manifold insert sealed interface effector and a second side defining a back plate sealed interface effector; and the manifold plate, the manifold insert, the molten material conduit device and the back plate are cooperatively configured such that: at least a portion of the base flange is disposed between the manifold insert and the back plate; a first sealed interface is established between the manifold insert sealed interface effector and the manifold; a second sealed interface is established between the back plate-sealed interface effector and the back plate; and the discharge opening is disposed in alignment with the molten material-receiver such that communication between the inlet opening of the molten material conduit device and the molten material receiver is established.
- An injection molding apparatus for receiving molten material from an injection machine nozzle of an injection molding machine, and delivering the molten material to at least one mold cavity housed within a cavity side of a mold assembly, comprising: a manifold insert defining a molten material receiver and at least one passageway; a manifold plate configured for receiving the manifold insert; a molten material conduit device having an inlet opening for receiving the molten material from the injection machine nozzle, a discharge opening for transmitting the molten material to the molten material receiver, and a molten material conduit extending therebetween; and a back plate having a molten material conduit device engaging flange defining a molten material conduit device receiving opening, the back plate configured for disposition on the manifold plate and for cooperating with the injection machine nozzle; wherein: the molten material conduit device includes a base flange extending outwardly from the discharge opening, the base flange defining: a manifold insert sealed interface effector; and an aligner; and the manifold insert, the manifold plate, the molten material conduit device and the back plate are cooperatively configured such that: the manifold insert sealed interface effector is disposed in abutting contact with the manifold insert such that the discharge opening is disposed in communication with the molten material receiver; the back plate is disposed on the manifold plate such that the molten material conduit device extends through the molten material conduit device-receiving opening such that at least a portion of the base flange is disposed between the manifold insert and the back plate; and an edge surface of the aligner is disposed in abutting contact the molten material conduit device engaging flange with effect that the discharge opening is disposed in axial alignment with the molten material receiver.
- Reference will now be made, by way of example, to the accompanying drawings which show example embodiments of the present application, and in which:
-
FIG. 1 is a cross-sectional view through an injection molding apparatus according to an example embodiment of the present disclosure with an injection nozzle disposed for delivering molten material to the apparatus; -
FIG. 1A is another cross-sectional view of the injection molding apparatus, taken 90 degrees relative to the cross-sectional view ofFIG. 1 , with the injection nozzle removed and illustrating a manifold passageway; -
FIG. 2 is a detail cross-sectional side view of a molten material conduit device mounted within the injection molding apparatus, as shown inFIGS. 1 and 1A ; -
FIG. 3 is a bottom perspective view of the base of the molten material conduit device according to an example embodiment of the present disclosure; -
FIG. 4 is a perspective top view of the molten material conduit device; -
FIG. 5 is a bottom, perspective view of the molten material conduit device with mounting screws in place; -
FIG. 6 is a top plan view of the injection molding apparatus ofFIGS. 1-1A illustrating the injection nozzle seat provided by the molten material conduit device; -
FIG. 7 is a cross sectional view through the injection molding apparatus illustrating the communication between the molten material conduit device and a mold cavity via the manifold; and -
FIG. 8 is a perspective, cross-sectional view of the injection molding apparatus illustrating the mounting of the molten material conduit device relative to the manifold. - Similar reference numerals may have been used in different figures to denote similar components.
- With reference to
FIGS. 1-9 , there is shown aninjection molding apparatus 100 according to an example embodiment of the present disclosure. Theinjection molding apparatus 100 is configured for delivering molten material from aninjection machine nozzle 110 of an injection molding machine to amold cavity 112 that is formed within thecavity side 103 of amold assembly 102 of theinjection molding apparatus 100. In some embodiments, thecavity side 103 of themold assembly 102 includes a plurality ofmold cavities 112, theinjection machine nozzle 110 delivering molten material to the plurality ofmold cavities 112 housed within thecavity side 103 of themold assembly 102 via a network of passageways formed within theinjection molding apparatus 100. - Referring now to
FIG. 1 , theinjection molding apparatus 100 includes amanifold 114, for cooperating with thecavity side 103 of themold assembly 102. In general, themanifold 114 is configured for delivering molten material to the one ormore mold cavities 112 housed within thecavity side 103 of themold assembly 102. In the example embodiment illustrated inFIGS. 1 and 1A , themanifold 114 is made up of amanifold insert 114A disposed within acorresponding manifold plate 114B. In such example embodiment, themanifold insert 114A is configured for delivering molten material to the one ormore mold cavities 112 housed within thecavity side 103 of the mold assembly, while the manifold plate 114 b is configured for supporting themanifold insert 114A and stationing themanifold insert 114A in position relative to the mold assembly. Accordingly, in such embodiments, the manifold insert 114A together with themanifold plate 114B make-up themanifold 114 with themanifold insert 114A defining the network of passageways formed within theinjection molding apparatus 100 for delivering the molten material, received from theinjection machine nozzle 110, to the one ormore mold cavities 112. It will be understood, however, that in some example embodiments, themanifold 114 may have different configurations and that themanifold 114 is not necessarily limited to a configuration including a manifold insert disposed within a corresponding manifold plate. - With reference, in particular, to the example embodiment illustrated in
FIGS. 1, 7 and 8 , themanifold plate 114B is configured to receive themanifold insert 114A. Accordingly, in some embodiments, for example, themanifold plate 114B includes areceiving cavity 1114 configured for receiving themanifold insert 114A. Themanifold insert 114A includes at least onepassageway 118 for distributing the molten material received from theinjection machine nozzle 110 to the one ormore mold cavities 112. Themanifold insert 114A is installed within thereceiving cavity 1114 of themanifold plate 114B. Accordingly, molten material delivered to themanifold insert 114A is transmitted through themanifold insert 114A, to thecavity side 103 of themold assembly 102. In this respect, themanifold insert 114A communicates with an inlet on thecavity side 103 of themold assembly 102, when theinjection molding apparatus 100 is in a closed condition, for transmitting the molten material to thecavity side 103 of the mold assembly. Therefore, themanifold insert 114A is installed within themanifold plate 114B, such that while theinjection molding apparatus 100 is in a closed condition and molten material is supplied to theapparatus 100 by theinjection machine nozzle 110, molten material received at themanifold insert 114A travels through themanifold insert 114A, housed within and supported by themanifold plate 114B, to the one ormore mold cavities 112. Accordingly, it will be understood that themanifold 114 serves to receive molten material from theinjection machine nozzle 110 and distribute the molten material to the one ormore mold cavities 112 housed within thecavity side 103 of themold assembly 102 of theinjection molding apparatus 100 through amanifold insert 114A disposed within and supported by a manifold plate 114 b, or any other suitable configuration. - With reference now to the example embodiment illustrated in
FIGS. 1 and 1A wherein themanifold 114 includes amanifold insert 114A installed within amanifold plate 114B, themanifold plate 114B has afirst side 113 that is configured for mating contact with thecavity side 103 of themold assembly 102, thefirst side 113 of themanifold plate 114, therefore, defining a molten material delivery side of themanifold 114 wherein the molten material delivery side of the manifold communicates the molten material, that is received from theinjection machine nozzle 110, to the one ormore mold cavities 112 housed within thecavity side 103 of themold assembly 102. Thesecond side 115 of themanifold plate 114B, which is disposed opposite to thefirst side 113, serves as the molten material-receiving side of themanifold 114 and is configured for mating contact with and being secured to aback plate 120 that encloses or seals the molten material-receiving side of themanifold 114. In the subject example embodiment wherein themanifold 114 includes amanifold insert 114A installed within amanifold plate 114B, themanifold insert 114A includes a molten material receiver, or inlet, 116 that is configured for receiving a supply of molten material that is delivered to theinjection molding apparatus 100 via theinjection machine nozzle 110. The moltenmaterial receiver 116 communicates with the at least onepassageway 118 that extends through themanifold insert 114A, from the moltenmaterial receiver 116, which communicates with a corresponding inlet on thecavity side 103 of themold assembly 102 for establishing communication between themanifold insert 114A and thecavity side 103 of themold assembly 102. - In some embodiments, for example, the at least one
passageway 118 defined in themanifold insert 114A is part of a network ofpassageways 1118 that are interconnected for distributing the molten material received at the moltenmaterial receiver 116 through themanifold insert 114A to the one ormore mold cavities 112 housed within thecavity side 103 of the mold assembly 102.With reference, again, to the example embodiment illustrated inFIGS. 1 and 1A , theback plate 120 is configured for mounting on and being secured to the second, molten material-receivingside 115 of the manifold plate 114 b. Accordingly, theback plate 120 has a manifoldengaging side 122 that is configured for mating contact with thesecond side 115 of the manifold plate 114 b such that a sealed interface is effected therebetween. Theback plate 120 also has a machinenozzle engaging side 124 that is disposed opposite to the manifoldengaging side 122, wherein the machinenozzle engaging side 124 is configured for engaging theinjection machine nozzle 110 of theinjection molding apparatus 100 so that theinjection machine nozzle 110 can deliver molten material to theinjection molding apparatus 100. With reference now toFIGS. 1, 1A andFIGS. 2-5 , in order to effect transmission of the molten material from theinjection machine nozzle 110 to themanifold insert 114A, theinjection molding apparatus 100 includes a moltenmaterial conduit device 130. The moltenmaterial conduit device 130 is configured for engaging with theinjection machine nozzle 110 for receiving the molten material from theinjection machine nozzle 110, and for delivering the supply of molten material received from theinjection machine nozzle 110 to the at least one passageway 118 (or network of passageways 1118) in themanifold insert 114A, via communication with the moltenmaterial receiver 116. The moltenmaterial conduit device 130 has aninlet end 132 that defines aninlet opening 134, for engaging with theinjection machine nozzle 110, anddischarge end 136 defining adischarge opening 138 for delivering the supply of molten material received at theinlet opening 134 to the moltenmaterial receiver 116. A moltenmaterial conduit 140 extends between and interconnects the inlet opening 134 and thedischarge opening 138. Accordingly, the moltenmaterial conduit device 130 is configured for disposition on themanifold insert 114A such that thedischarge end 136 is disposed in abutting contact with themanifold insert 114A with effect that the that the discharge opening 138 of the moltenmaterial conduit device 130 is aligned with and disposed in communication with the moltenmaterial receiver 116. When theback plate 120 is mounted on the manifold plate 114 b of themanifold 114, the moltenmaterial conduit device 130 extends through theback plate 120 such that theinlet end 132 andinlet opening 134 remain exposed and accessible from the machinenozzle engaging side 124 of theback plate 120 for engagement with theinjection machine nozzle 110. Accordingly, the moltenmaterial conduit device 130 may vary in length depending on the particular application and/or overall design of theback plate 120 and/or theinjection molding apparatus 100. In some embodiments, for example, the moltenmaterial conduit device 130 is a sprue bar. - In order to secure the
inlet end 132 of the moltenmaterial conduit device 130 in position relative to theback plate 120, in some embodiments, for example, theinjection molding apparatus 100 includes a locatingring 300 for supporting theinlet end 132 of the moltenmaterial conduit device 130 in position relative to the machinenozzle engaging side 124 of theback plate 120. In some embodiments, for example, the locatingring 300 also serves to locate theinlet end 132 and the inlet opening 134 relative to the machine nozzle-engagingside 124 of theback plate 120 to facilitate proper alignment of theinjection machine nozzle 110 with the inlet opening 134 of the moltenmaterial conduit device 130. In some embodiments, for example, the locatingring 300 includes acentral opening 301 for receiving theinlet end 132 of the moltenmaterial conduit device 130. In some embodiments, for example, theinlet end 132 of the moltenmaterial conduit device 130 is received within thecentral opening 301 of the locatingring 300 such that a sealedinterface 303 is effected between the locatingring 300 and theinlet end 132 of the moltenmaterial conduit device 130 such that the molten material discharged from theinjection machine nozzle 110 is directed solely through theinlet opening 134 andmolten material conduit 140 of the moltenmaterial conduit device 130. Accordingly, in some embodiments, the sealedinterface 303 between theinlet end 132 of the moltenmaterial conduit device 130 and the corresponding edge surface defined by thecentral opening 301 in the locatingring 300 serves to prevent molten material from seeping between the moltenmaterial conduit device 130 and theback plate 120 into the manifold 114 ormanifold insert 114A. In some embodiments, for example, the locatingring 300 has a sloping or concave surface 302 that extends around thecentral opening 301 for providing sufficient clearance to allow for proper engagement of theinjection machine nozzle 110 against theinlet end 132 and inlet opening 134 of the moltenmaterial conduit device 130. - In use, when the
injection molding apparatus 100 is disposed in a closed condition wherein the moltenmaterial delivery side 113 of the manifold plate 114 b is disposed in abutting contact with thecavity side 103 of themold assembly 102, theinjection machine nozzle 110 is moved into engagement with theinlet end 132 of the moltenmaterial conduit device 130 for delivering a supply of molten material to theinjection molding apparatus 100 via theinlet opening 134. Once the molten material is delivered to the one ormore mold cavities 112 housed within thecavity side 103 of themold assembly 102, theinjection machine nozzle 110 is moved out of engagement with theinlet end 132 of the moltenmaterial conduit device 130 and the molten material is allowed to cure within the mold cavities to form the molded article(s). Once the molten material has cured, theinjection molding apparatus 100 is opened and the molded article(s) ejected or otherwise removed from themold assembly 102 and the injection molding cycle can continue. - In some prior art configurations, continued operation of an injection molding apparatus can result in misalignment of the sprue bar (or other molten material conduit device) relative to the manifold (or manifold insert). Misalignment of the sprue bar (or other molten material conduit device) relative to the manifold (or manifold insert) may occur due to the repeated cycling of the injection machine nozzle being brought into contact with the inlet end of the sprue bar (or other molten material conduit device), which in some instances, may result in dislodging or displacement of the sprue bar (or other molten material conduit device) relative to the manifold or manifold insert. In some prior art configurations, the mounting of the sprue bar relative to the manifold is such that the sprue bar is prone to rotation about an axis that extends normal to the injection axis in response to the forces applied to the sprue bar by the repeated engagement of the injection machine nozzle with the injection molding apparatus against the inlet end of the sprue bar. Any displacement, or rotation, of the sprue bar relative to the manifold (or manifold insert) can result in the sprue bar separating from the manifold or manifold insert and/or misalignment of the sprue bar relative to the inlet to the manifold (or manifold insert) which may lead to unwanted leakage of molten material within with manifold or mold assembly thereby damaging the mold.
- In the subject example embodiment, the molten
material conduit device 130 is configured for secure mounting relative to themanifold insert 114A within theinjection molding apparatus 100 in an effort to maintain proper alignment of the moltenmaterial conduit device 130 relative to themanifold insert 114A over repeated operating cycles of theinjection molding apparatus 100 to reduce the likelihood of leakage of molten material within theinjection molding apparatus 100 and mitigate the potential damage cause by any leakage that may occur. With reference, in particular to the example embodiment illustrated inFIGS. 1 and 1A , the moltenmaterial conduit device 130 is disposed relative to the manifold 114 such that thedischarge end 136 of the moltenmaterial conduit device 130 is disposed in abutting contact with themanifold insert 114A. Disposition of thedischarge end 136 of the moltenmaterial conduit device 130 in abutting contact with themanifold insert 114A is with effect that the discharge opening 138 of the moltenmaterial conduit device 130 is aligned with and disposed in communication with themolten material receiver 116 formed in themanifold insert 114A. Thedischarge end 136 of the moltenmaterial conduit device 130 is also configured for effecting a sealed interface between the moltenmaterial conduit device 130 and the manifold 114, ormanifold insert 114A. Accordingly, in some embodiments, for example, the moltenmaterial conduit device 130 includes abase flange 160 that extends around and away from thedischarge opening 136, thebase flange 160 having afirst side 161 configured for disposition in face-to-face, abutting contact with themanifold insert 114A for effecting a sealed interface with themanifold insert 114A. The moltenmaterial conduit device 130, therefore, includes a manifold insert sealedinterface effector 142, that is defined by thefirst side 161 or bottom surface of thebase flange 160 of thedischarge end 136, wherein the manifold insert sealedinterface effector 142 is for effecting a first sealedinterface 142A with the manifold insert. - In some embodiments, for example, the
base flange 160 extends radially outwardly from thedischarge opening 138 defined by the moltenmaterial conduit device 130 such that the manifold insert sealedinterface effector 142 defines an annular area wherein the annular area has an inner radius, R1, as measured from the central axis of thedischarge opening 138 to the circumference of the discharge opening 138 (which corresponds to the radius of the discharge opening 138), and an outer radius, R2, as measured from the central axis of thedischarge opening 138, along the first side orbottom surface 161 of thebase flange 160 to anouter edge 163 of thebase flange 160 defined by thedischarge end 136 of the moltenmaterial conduit device 130. In some embodiments, for example, the inner radius, R1, is between a minimum of 6.35 mm to a maximum of 25.4 mm. In some embodiments, for example, the outer radius, R2, is between a minimum of 38.1 mm to maximum of 57.15 mm. - In some embodiments, for example, in order to assist with positioning of the molten
material conduit device 130 relative to themanifold insert 114A, and with alignment of thedischarge opening 138 relative to themolten material receiver 116, molten materialconduit device engagers 196 are employed for engaging thedischarge end 136 of the moltenmaterial conduit device 130 and locating the moltenmaterial conduit device 130 relative to themanifold insert 114A while the moltenmaterial conduit device 130 is mounted on themanifold insert 114A. In some embodiments, for example, the molten materialconduit device engagers 196 have afirst end 197 configured for engaging themanifold insert 114A and a second,opposite end 198 configured for engaging the bottom surface orfirst side 161 of thebase flange 160. Accordingly, in some embodiments, for example, themanifold insert 114A includes one or more engager-receivers, or openings, 200 configured for receiving the correspondingfirst end 197 of the molten materialconduit device engagers 196. Similarly, thebase flange 160 of thedischarge end 136 includes one or more engager-receivers (or openings) 202 configured for receiving the correspondingsecond end 198 of a respective one of the molten materialconduit device engagers 196. The mating engagement between the molten materialconduit device engagers 196 with both themanifold insert 114A and the discharge end, orbase flange 160, of the moltenmaterial conduit device 130 serves to locate the moltenmaterial conduit device 130 relative to themanifold insert 114A and hold the moltenmaterial conduit device 130 in position relative to themanifold insert 114A during assembly of theinjection molding apparatus 100. In some embodiments, for example, the molten material conduit device-engagers 196 are dowel pins. - As described above, once the molten
material conduit device 130 is positioned on themanifold insert 114A, theback plate 120 is disposed on the manifold plate 114 b, with at least a portion of the moltenmaterial conduit device 130 extending therethrough, for enclosing and sealing against the second, molten material-receivingside 115 of the manifold plate 114 b. Referring again toFIGS. 1, 1A and 2 , in order to further secure the moltenmaterial conduit device 130 in position within theinjection molding apparatus 100, thedischarge end 136 of the moltenmaterial conduit device 130 is configured for engaging with theback plate 120 such that at least a portion of thebase flange 160 is disposed intermediate, or is pinched between, themanifold insert 114A and theback plate 120. Accordingly, in some embodiments, for example, thedischarge end 136 of the moltenmaterial conduit device 130 includes a back-plate engager 144 that is configured for engagement between themanifold insert 114A and theback plate 120 such that a second sealedinterface 153 is effected between at least a portion of thesecond side 162 of thebase flange 160 and the manifoldengaging side 122 of theback plate 120. In the subject example embodiment, the back plate-engager 144 includes at least a portion of thebase flange 160. - In order to effect engagement between the
discharge end 136 of the moltenmaterial conduit device 130 and theback plate 120 such that the back-plate engager 144 is disposed or pinched between themanifold insert 114A and theback plate 120, theback plate 120 includes a molten material conduitdevice engaging flange 152 that defines a molten material conduit device-receivingopening 150. The molten material conduitdevice engaging flange 152 is configured such that as theback plate 120 is mounted on the manifold 114 and disposed in abutting contact with the manifold plate 114 b, the moltenmaterial conduit device 130 extends through the molten material conduit device-receivingopening 150. The moltenmaterial conduit device 130 and the molten material conduit device-engagingflange 152 are cooperatively configured such that, while the moltenmaterial conduit device 130 is mounted on themanifold insert 114A in communication with themolten material receiver 116 and theback plate 120 is mounted on the manifold plate 114 b, the molten material conduit device-engagingflange 152 engages with and is disposed in abutting contact with theback plate engager 144. Accordingly, disposition of theback plate 120 on the manifold plate 114 b such that the moltenmaterial conduit device 130 extends through the molten material conduit device-receivingopening 150 is with effect that the molten material conduit device-engagingflange 152 engages with and is disposed in abutting contact with theback plate engager 144 of the moltenmaterial conduit device 130 such that a sealedinterface 153 is effected between the molten material conduit device-engagingflange 152 defined by the back plate 12 and the portion of thesecond side 162 of thebase flange 160 that defines the corresponding surface ofback plate engager 144. Accordingly, in some embodiments, for example, thedischarge end 136 of the moltenmaterial conduit device 130 defines a back plate sealedinterface effector 164. - In some embodiments, for example, disposition of the
back plate 120 in abutting contact with the manifold plate 114 b, and thedischarge end 136 of the moltenmaterial conduit device 130, is with effect that pressure is applied to theback plate engager 114 due to the “pinching” of theback plate engager 144 between the molten material conduit device-engagingflange 152 defined by theback plate 120 and themanifold insert 114A. In some embodiments, for example, the pressure applied to theback plate engager 144, by theback plate 120, contributes to the establishment of the first sealedinterface 142A between the manifold insert sealedinterface effector 142 and themanifold insert 114A. In some embodiments, for example, the pressure applied to theback plate engager 144, by theback plate 120, also contributes to the establishment of the second sealedinterface 153 between the back plate sealedinterface effector 164 defined by thedischarge end 136 of the moltenmaterial conduit device 130 and the molten material conduit device-engagingflange 152 of theback plate 120. Establishment of the first sealed interface 142 a between the manifold insert sealedinterface effector 142 defined by thebase flange 160 of thedischarge end 136 of the moltenmaterial conduit device 130 is with effect that leakage of molten material from thedischarge opening 138 between the manifold insert sealedinterface effector 142 defined by thebase flange 160 of thedischarge end 136 of the moltenmaterial conduit device 130 and themanifold insert 114A is resisted. Establishment of the second sealedinterface 153 between the back plate sealedinterface effector 162 defined by theback plate engager 144 of thedischarge end 136 of the moltenmaterial conduit device 130 and the corresponding surface defined by the molten material conduit device-engagingflange 152 of theback plate 120 is with effect that, should leakage of molten material exterior to the moltenmaterial conduit device 130 occur (for instance if leakage of molten material occurs between theinlet end 132 of the moltenmaterial conduit device 130 and the locating ring 300), further infiltration of this molten material into theinjection molding apparatus 100 between theback plate 120 and the manifold plate 114 b is resisted. - In some embodiments, for example, the
discharge end 136 of the moltenmaterial conduit device 130 includes arelief passage 170 that extends through thedischarge end 136 of the moltenmaterial conduit device 130 for directing molten material away from the sealedinterface 142A established between thedischarge end 136 of the moltenmaterial conduit device 130 and themanifold insert 114A towards the machine nozzle-engagingside 124 of the back plate 120 (or the back side of the injection molding apparatus 100). Therelief passage 170 is configured such that, in the event that leakage of molten material from the discharge opening 138 of the moltenmaterial conduit device 130 between the manifold insert sealedinterface effector 142 defined by thebase flange 160 and the corresponding surface of themanifold insert 114A occurs with effect that the sealedinterface 142A established by the abutting contact between the manifold insert sealedinterface effector 142 and themanifold insert 114A is defeated, the leaking molten material is directed through therelief passage 170, towards the second, or machine nozzle-engagingside 124 of the back plate 120 (or back side of the injection molding apparatus 100). By directing any leaking molten material towards the second, or machine nozzle-engagingside 124 of the back plate 120 (or back side of the injection molding apparatus 100), the leaking molten material is directed away from themanifold insert 114A and any passageways that are contained within themanifold insert 114A that are not intended for the influx of molten material. Directing the leaking molten material away from themanifold insert 114A and away from any passageways contained within themanifold insert 114A or manifold plate 114 b that are not intended for the influx of molten material also helps to direct any leakage of molten material away from auxiliary equipment and any related wiring, for example heaters, contained within themanifold insert 114A, or within any other parts of themold assembly 102 orinjection molding apparatus 100 with helps to mitigate overall damage to themold assembly 102 orinjection molding apparatus 100. - With reference now to
FIGS. 3 and 4 , in some embodiments, for example, disposition of theback plate 120 on the manifold plate 114 b with the moltenmaterial conduit device 130 extending through the molten material conduit device-receivingopening 150 such that theback plate engager 144 is pinched between themanifold insert 114A and theback plate 120 is also with effect that the discharge opening 138 of the moltenmaterial conduit device 130 is aligned with themolten material receiver 116. Alignment of thedischarge opening 138 with themolten material receiver 116 establishes communication between the inlet opening 134 of the moltenmaterial conduit device 130 with themolten material receiver 116 such that, when a supply of molten material is delivered to theinlet opening 134, the molten material is directed to themolten material receiver 116 by way of themolten material conduit 140 and the discharge opening 138 of the moltenmaterial conduit device 130. - As shown in
FIG. 3 , in some embodiments, for example, therelief passage 170 includes agroove 172 disposed within thefirst side 161 or manifold insert sealedinterface effector 142 of thebase flange 160 of the moltenmaterial conduit device 130, thegroove 172 extending around thedischarge opening 138. Thegroove 172 extends into, or is recessed into, thebottom surface 161, or the manifold insert sealedinterface effector 142, defined by thebase flange 160 such that, when the moltenmaterial conduit device 130 is disposed in mating contact with themanifold insert 114A, there is an absence of contact between thebottom surface 161 of thedischarge end 136 and themanifold insert 114A in the region defined by thegroove 172. - A plurality of
relief openings 174 are disposed at spaced apart intervals about thegroove 172, the plurality ofrelief openings 174 extending through thedischarge end 136 of the moltenmaterial conduit device 130 from the recessed area defined by thegroove 172 to the back (or rear surface) orsecond side 162 of thedischarge end 136. The plurality ofrelief openings 174 are disposed about thegroove 172 such that, while the moltenmaterial conduit device 130 is mounted on themanifold insert 114A and theback plate 120 is mounted on the manifold plate 114 b, each of the plurality ofrelief openings 174 is unobstructed by, or remains free from interference from, the molten conduitdevice engaging flange 152 defined by theback plate 120. Accordingly, thegroove 172 and the plurality ofrelief openings 174 are cooperatively configured such that, while the moltenmaterial conduit device 130 is mounted on themanifold insert 114A, thegroove 172 faces themanifold insert 114A such that any leakage of molten material between the manifold insert sealedinterface effector 142 defined by thebase flange 160 and themanifold insert 114A will enter or flow into the recessed area defined by thegroove 172. Molten material entering thegroove 172 will travel around thegroove 172 until the molten material reaches one or more of theplurality relief openings 174 disposed in communication with thegroove 172. Once the molten material reaches the one or more of theplurality relief openings 174, the molten material passes through the one ormore relief openings 174 and out through the second orrear side 162 of thedischarge end 136 of the moltenmaterial conduit device 130 towards the exterior of theinjection molding apparatus 100. Accordingly, molten material that enters thegroove 172 and that travels through the one or more of the plurality ofrelief openings 174 is directed away from the remaining portion of the sealed interface 142 a that is effected between the manifold insert sealedinterface effector 142 and themanifold insert 114A thereby maintaining at least a portion of the sealedinterface 142A between thedischarge end 136 and themanifold insert 114. By ensuring that at least a portion of the sealedinterface 142A remains effective in the event that there is some leakage of molten material from thedischarge opening 138 between thedischarge end 136 of the moltenmaterial conduit device 130 and themanifold insert 114A and diverting any leakage of molten material away from critical areas of themanifold insert 114A, the potential damage due to unwanted influx of molten material into critical areas of the manifold insert is reduced. - In some embodiments, for example, the
injection molding apparatus 100 includes a backplate relief passage 190 for directing any leakage of molten material to the exterior of theinjection molding apparatus 100. The back plate-relief passage 190 extends within theback plate 120 and is open to the region surrounding the moltenmaterial conduit device 130 into which the plurality ofrelief openings 174 discharge. Accordingly, any leakage of molten material within theapparatus 100 that is diverted away from the sealedinterface 142A through thegroove 172 and the plurality ofrelief openings 174 into the region surrounding the moltenmaterial conduit device 130 will be easily identified by operators of theinjection molding apparatus 100 once the molten material escapes through the backplate relief passage 190. Early identification of leakage of molten material within theinjection molding apparatus 100 can serve to mitigate and/or reduce the overall damage to themanifold insert 114A and/or other critical components of theinjection molding apparatus 100 caused by the leakage of molten material. - Referring in particular to
FIG. 4 , in some embodiments, for example, the moltenmaterial conduit device 130 further includes analigner 180 for effecting alignment of the discharge opening 138 of the moltenmaterial conduit device 130 with themolten material receiver 116 during assembly of theinjection molding apparatus 100. In some embodiments, for example, thealigner 180 is configured for cooperating with the molten material conduit device-engagingflange 152 that is defined by theback plate 120. Thealigner 180 cooperates with the molten material conduit device-engagingflange 152 such that, while the moltenmaterial conduit device 130 is disposed on themanifold insert 114A and theback plate 120 is disposed on the manifold plate 114 b, anedge surface 156 of the molten material conduit device-engagingflange 152 is disposed in abutting contact engagement with anedge surface 182 of thealigner 180. Disposition of theedge surface 156 of the molten material conduit device-engagingflange 152 in abutting contact with thecorresponding edge surface 182 of thealigner 180 is with effect that, the centrallongitudinal axis 131 of the moltenmaterial conduit device 130, which extends through themolten material conduit 140 and the discharge opening 138 of the moltenmaterial conduit device 130, is disposed in axial alignment with the central axis of themolten material receiver 116. Alignment of the centrallongitudinal axis 131 of themolten material conduit 140 and thedischarge opening 138 with the central axis of themolten material receiver 116 helps to reduce the potential for leakage of molten material within themanifold insert 114A since molten material supplied to the inlet opening 134 of the moltenmaterial conduit device 130, by theinjection machine nozzle 110, is transmitted directly to themolten material receiver 116, via thedischarge opening 138. Any misalignment of the discharge opening 138 of the moltenmaterial conduit device 130 with themolten material receiver 116 can result in leakage of molten material from the discharge open 138 between the manifold insert sealedinterface effector 142 and themanifold insert 114A resulting in damage to themanifold insert 114A and theinjection molding apparatus 100. - Referring, in particular, to
FIGS. 2 and 4 , in some embodiments, for example, thealigner 180 is in the form of a boss that projects from thebase flange 160, opposite to the manifold insert sealedinterface effector 142 about the molten material conduit portion of the moltenmaterial conduit device 130 and is configured to be received within the molten material conduit device-receivingopening 150 defined in the manifold plate 114 b. In some embodiments, for example, thealigner 180 extends from thesecond side 162 of thebase flange 160 such that thebase flange 160 has a stepped profile. In some embodiments, thealigner 180 is circular and extends radially outwardly from the base of the molten material conduit portion of the moltenmaterial conduit device 130. Accordingly, in some embodiments, thealigner 180 has a radius, RA, as measured from the centrallongitudinal axis 131 of the moltenmaterial conduit device 130 to theedge surface 182 defined by thealigner 180. Accordingly, the radius, RA, of thealigner 180 is selected relative to the outer radius, R2, of thebase flange 160, to ensure that at least a portion of thebase flange 160 extends beyond theedge surface 182 of thealigner 180 thereby defining theback plate engager 144. The radius, R2, of thebase flange 160, therefore, is greater than the radius, RA, defined by thealigner 180 such that the portion of thebase flange 160 that extends beyond thealigner 180 and defines theback plate engager 144 has sufficient surface area to be sandwiched or pinched between the manifold 114 and theback plate 120 and define a sealed interface between the back plate sealedinterface effector 164 and the corresponding surface of theback plate 120. In some embodiments, for example, the radius, RA, of thealigner 180 is selected such that it is between a minimum of at least 31.75 mm to a maximum of 50.8 mm. In some embodiments, for example, the moltenmaterial conduit device 130 is configured such that the ratio of the outer radius, R2, of thebase flange 160 to the radius, RA, of thealigner 180 is anywhere between at least 1:1.1 and 1:1.2. - While the example embodiment illustrated in
FIG. 4 shows thebase flange 160 and thealigner 180 being circular, it will be understood that other configurations, such as square or hexagonal, for example, are contemplated within the scope of the present disclosure, provided that thealigner 180 is configured such that it is received within the molten material conduit device-receivingopening 150 with theedge surface 182 of thealigner 180 disposed in abutting contact with theedge surface 156 of the molten material conduit device-receivingopening 156 with effect that thedischarge opening 138 is axially aligned with themolten material receiver 116. Additionally, while in the subject example embodiment, thealigner 180 forms part of thebase flange 160 and is integrally formed with the moltenmaterial conduit device 130, in some embodiments, for example, thealigner 180 may be separately formed and is otherwise fixed or secured to thebase flange 160 or moltenmaterial conduit device 130. - While the
aligner 180 serves to align the moltenmaterial conduit device 130 relative to themanifold insert 114A and theback plate 120 such that thedischarge opening 138 is aligned with themolten material receiver 116, and the inlet opening 134 of theinlet end 132 is aligned relative to theback plate 120, in some embodiments, thealigner 180 also serves to restrict possible rotation of the moltenmaterial conduit device 130 relative to themanifold insert 114A that may occur due to the forces applied to theinlet end 132 of the moltenmaterial conduit device 130 in response to repeated engagement of theinjection machine nozzle 110 against theinlet end 132 of the moltenmaterial conduit device 130. In this respect, disposition of theback plate 120 on the manifold plate 114 b such that the molten material conduit device-engagingflange 152 is disposed in abutting contact with the back plate-sealedinterface effector 164 defined by theback plate engager 144 such that theedge surface 156 of the molten material conduit device-engagingflange 152 is disposed in abutting contact with thecorresponding edge surface 182 of thealigner 130, is with effect that rotation of the moltenmaterial conduit device 130 relative to themanifold insert 114A about an axis that extends normal to the central longitudinal axis 133 of themolten material conduit 140 of the molten material conduit device 130 (or the injection axis of the injection machine nozzle 110) is resisted due to the interference between thedischarge end 136 of the moltenmaterial conduit device 130 and the molten material conduit device-engagingflange 152. Specifically, in some embodiments, for example, rotation of the moltenmaterial conduit device 130 relative to themanifold insert 114A about an axis that extends normal to the central longitudinal axis 133 of themolten material conduit 140 of the moltenmaterial conduit device 130 is resisted due to the interference between theback plate engager 144 and the molten material conduitdevice engaging flange 152 as well as due to interference between thealigner 180 and theback plate 120, specifically, theedge surface 182 of thealigner 180 impinging against the correspondingedge surface 156 defines by the molten material conduitdevice engaging flange 152. Accordingly, it will be understood that the pinching of theback plate engager 144 portion of thebase flange 160 of thedischarge end 136 of the moltenmaterial conduit device 130 between themanifold insert 114A not only serves to align the discharge opening 138 of the moltenmaterial conduit device 130 with themolten material receiver 116 and establish a sealed interface between thedischarge end 136 of the moltenmaterial conduit device 130 with themanifold insert 114A and theback plate 120, but also serves to maintain the alignment of thedischarge opening 138 with themolten material receiver 116 over repeated injection cycles during continued operation of theinjection molding apparatus 100. - Referring in particular to
FIGS. 3-5 , in some embodiments, for example, in order to further secure the moltenmaterial conduit device 130 to themanifold insert 114A,fasteners 208 are used for fastening, or further securing, the moltenmaterial conduit device 130 to themanifold insert 114A. Accordingly, in some embodiments,fasteners 208 are inserted throughcorresponding fastener openings 204 that are formed in and extend through thedischarge end 136 of the moltenmaterial conduit device 130. In the subject example embodiment, thefastener openings 204 are disposed in thedischarge end 136 of the moltenmaterial conduit device 130 and extend through thealigner 180 andbase flange 160 from thetop surface 188 of thealigner 180 through to the bottom surface orfirst surface 161 of thebase flange 160, as shown for instance inFIGS. 3-5 . The manifold insert 114A includes corresponding fastener openings 206 that cooperate with thefasteners 208 such that when the moltenmaterial conduit device 130 is disposed on themanifold insert 114A, thefastener openings 204 on the moltenmaterial conduit device 130 align with the fastener openings 206 on themanifold insert 114A and the correspondingfasteners 208 extend through the alignedfastener openings 204, 206 securing the moltenmaterial conduit device 130 to themanifold 114. In some embodiments, for example, thefastener openings 204, 206 are threaded openings for cooperating with corresponding threadedfasteners 208. However, given that the moltenmaterial conduit device 130 is also secured in position relative to themanifold insert 114A and backplate 120 by means of the disposition of theback plate engager 144 between themanifold insert 114A and the molten material conduitdevice engaging flange 152, and the abutting contact between theedge surface 182 of thealigner 180 and thecorresponding edge surface 156 of the molten material conduitdevice engaging flange 152, the amount of force exerted by thefasteners 208 to secure the moltenmaterial conduit device 130 to themanifold insert 114A is minimized. Minimizing the amount of force exerted byfasteners 208 on thedischarge end 136 of the moltenmaterial conduit device 130 reduces the risk of an imbalance of forces being applied to thebase flange 160 that could have an adverse effect of the establishment of the sealedinterface 142A between the manifold insert sealedinterface effector 142 and themanifold insert 114A. In some embodiments, for example,fasteners 208 are not required where the clamping effect of theback plate 120 against the dischargedend 136 of the moltenmaterial conduit device 130 is sufficient to ensure stability of the moltenmaterial conduit device 130 relative to themanifold insert 114A. - Referring again to
FIG. 1A , in some embodiments, for example, in order to secure theback plate 120 to the manifold plate 114 b, backplate fasteners 220 are used that are configured to extend through corresponding fastener-receivingopenings back plate 120 and in the manifold plate 114 b. The securing of theback plate 120 to the manifold plate 114 b via theback plate fasteners 220 fixes theback plate 120 to the manifold plate 114 b effectively clamping theback plate 120 to the manifold plate 114 b. The clamping together of theback plate 120 and the manifold plate 114 b, by way of theback plate fasteners 220, is with effect that some of the clamping effect is transmitted to the moltenmaterial conduit device 130 via the molten material conduit device-engagingflange 152 for securing and stabilizing the moltenmaterial conduit device 130 in position relative to themanifold insert 114A and within theinjection molding apparatus 100. In some embodiments, theback plate fasteners 220 and the correspondingopenings longitudinal axis 131 of the moltenmaterial conduit device 130 by a radial distance, D, that is about five times greater than the radial distance, d, by which the molten materialconduit device fasteners 208 are spaced relative to the centrallongitudinal axis 131 of the centrallongitudinal axis 131. By having theback plate fasteners 220 spaced apart from the location of the moltenmaterial conduit device 130, the potential forback plate fasteners 220 to induce stress on thedischarge end 136 orbase flange 160 of the moltenmaterial conduit device 130, as torque is applied to theback plate fasteners 220 as they advance through the corresponding sets of receivingopenings base flange 160 as a result of thefasteners 220 being secured within the correspondingopenings discharge end 136 orbase flange 160 of the moltenmaterial conduit device 130 that can lead to misalignment of thedischarge opening 138 with themolten material receiver 116. As the securing of the moltenmaterial conduit device 130 relative to themanifold insert 114A is primarily effected by the clamping or “pinching” of theback plate engager 144 between the molten material conduit device-engagingflange 152 and does not rely onfasteners 220 being installed within close proximity to the moltenmaterial conduit device 130, thefasteners 220 can be installed at a greater distance away from the location of the moltenmaterial conduit device 130 which facilitates assembly of theinjection molding apparatus 100 since the potential for the creation of imbalanced forces on the moltenmaterial conduit device 130, as torque is applied to thefasteners 220, is reduced as a result of the positioning of thefasteners 220 relative to the moltenmaterial conduit device 130 within theinjection molding apparatus 100. For example, in a specific example embodiment wherein the radial distance, D, by which theback plate fasteners 220 are radially spaced apart from the centrallongitudinal axis 131 of the moltenmaterial conduit device 130 is 117 mm while the radial distance, d, between the centrallongitudinal axis 131 of the moltenmaterial conduit device 130 and the molten materialconduit device fasteners 208 is 22.98 mm, the force imparted by each of theback plate fasteners 220 is about 40700 lb while the force imparted by each of the molten materialconduit device fasteners 208 is about 9960 lb. By having the larger forces imparted by theback plate fasteners 220 spaced apart from the moltenmaterial conduit device 130, it has been found that the potential for imbalances at the moltenmaterial conduit device 130, that can give rise to leakage from the moltenmaterial conduit device 130 is reduced. Assembly of theapparatus 100 is also facilitated given that the higher forces are being applied at a greater distance away from the moltenmaterial conduit device 130. - While various embodiments of the
injection molding apparatus 100 have been described, it will be understood that certain adaptations and modifications of the described embodiments can be made. Therefore, the above discussed embodiments are considered to be illustrative and not restrictive.
Claims (27)
1. An injection molding apparatus for receiving molten material from an injection machine nozzle of an injection molding machine, and delivering the molten material to at least one mold cavity housed within a cavity side of
a mold assembly, comprising:
a manifold comprising:
a manifold plate; and
a manifold insert disposed within the manifold plate, the manifold insert including:
a molten material receiver configured for receiving molten material; and
at least one passageway for transmitting the molten material received at the molten material receiver to the at least one mold cavity;
a molten material conduit device having an inlet opening for receiving the molten material from the injection machine nozzle, a discharge opening for transmitting the molten material to the molten material receiver, and a molten material conduit extending therebetween; and
a back plate disposed on the manifold plate and configured for cooperating with the injection machine nozzle;
wherein:
the molten material conduit device includes a base flange extending outwardly from the discharge opening, the base flange having a first side defining a manifold insert sealed interface effector and a second side defining a back plate sealed interface effector; and
the manifold plate, the manifold insert, the molten material conduit device and the back plate are cooperatively configured such that:
at least a portion of the base flange is disposed between the manifold insert and the back plate;
a first sealed interface is established between the manifold insert sealed interface effector and the manifold insert;
a second sealed interface is established between the back plate-sealed interface effector and the back plate; and
the discharge opening is disposed in alignment with the molten material-receiver such that communication between the inlet opening of the molten material conduit device and the molten material receiver is established.
2. The injection molding apparatus as claimed in claim 1 ;
wherein:
the manifold plate, the manifold insert, the molten material conduit device and the back plate are cooperatively configured such that:
rotation of the molten material conduit device about an axis that is normal to a central longitudinal axis of the molten material conduit device is resisted in response to interference between the base flange and the back plate.
3. The injection molding apparatus as claimed in claim;
wherein:
the manifold plate includes a manifold insert receiving opening configured for receiving the manifold insert; and
disposition of the manifold insert within the manifold plate is such that:
while the injection molding apparatus is disposed for receiving molten material, the manifold plate and the manifold insert are co-operatively configured such that the manifold insert is disposed for delivering the molten material received at the molten material receiver to the at least one mold cavity.
4. The injection molding apparatus as claimed in claim 1 ;
wherein:
the back plate includes a manifold insert engaging side and an injection machine nozzle engaging side; and
disposition of the back plate on the manifold plate is with effect that the manifold insert engaging side is disposed in abutting contact with the manifold plate and the manifold insert.
5. (canceled)
6. The injection molding apparatus as claimed in claim 4 ;
wherein:
the back plate includes a molten material conduit device engaging flange defining a molten material conduit device receiving opening; and
disposition of the back plate on the manifold plate is with effect that:
the molten material conduit device extends through the molten material conduit device receiving opening; and
the molten material conduit device engaging flange is disposed in abutting contact with the back plate sealed interface effector.
7. The injection molding apparatus as claimed in claim 6 ;
wherein:
the molten material conduit device includes:
an aligner;
and
disposition of the back plate on the manifold plate such that the molten material conduit device extends through the molten material conduit device receiving opening and the molten material conduit device engaging flange is disposed in abutting contact with the back plate sealed interface effector, is with effect that the aligner is disposed in contact engagement with the molten material conduit device engaging flange.
8. The injection molding apparatus as claimed in claim 7 ;
wherein:
disposition of the aligner in contact engagement with the molten material conduit device engaging flange is such that an edge surface of the aligner is disposed in abutting contact with an edge surface of the molten material conduit device engaging flange with effect that:
the discharge opening is disposed in axial alignment with the molten material receiver.
9. The injection molding apparatus as claimed in claim 7 ;
wherein:
the aligner includes a boss extending from the second side of the base flange, such that the base flange has a stepped profile.
10. (canceled)
11. (canceled)
12. (canceled)
13. (canceled)
14. The injection molding apparatus as claimed in claim 1 ;
wherein:
the molten material conduit device includes:
a relief passage extending through the base flange from the first side to the second side, the relief passage having an inlet disposed in the manifold insert sealed interface effector and an outlet disposed on the second side of the base flange;
disposition of the back plate on the manifold plate is such that the outlet of the relief passage is unobstructed by the back plate; and
while the molten material conduit device is disposed on the manifold insert and the back plate is disposed on the manifold such that the first sealed interface and the second sealed interface are established; and
while the injection molding machine is disposed in a closed position wherein the injection molding apparatus is in communication with the at least one mold cavity and molten material is delivered to the molten material-receiver from the injection machine nozzle, via the molten material conduit device:
defeating of the first sealed interface such that molten material travels between the base flange and the manifold insert is with effect that the molten material is directed away from the manifold insert via the relief passage.
15. The injection molding apparatus as claimed in claim 14 ;
wherein:
the relief passage includes:
a groove disposed within the first side of the base flange and around the discharge opening, the manifold insert sealed interface effector extending on either side of the groove; and
a plurality of relief openings disposed at spaced apart intervals about the groove and extending through the base flange, each relief opening having a first open end in communication with the groove and a second open end disposed in the second side of the base flange.
16. The injection molding apparatus as claimed in claim 1 ;
further comprising:
plurality of molten material conduit device engagers having a first end for engaging the first side of the base flange and a second end for engaging the manifold insert;
wherein:
the base flange includes a plurality of engager-receivers, wherein each engager-receiver is configured for receiving the first end of a corresponding one of the plurality of molten material conduit device engagers; and
the manifold insert includes a plurality of engager-receivers, wherein each engager-receiver is configured for receiving the second end of the conduit device engager;
and
the molten material conduit device, the manifold insert and the molten material conduit device engagers are cooperatively configured such that:
disposition of the molten material conduit device on the manifold insert is with effect that:
the first end of each of the molten material conduit device engagers is received within the corresponding engager-receiver disposed in the base flange;
the second end of each of the molten material conduit device engagers is received within the corresponding engager-receiver disposed in manifold insert;
the discharge opening is axially aligned with the molten material receiver; and
displacement of the molten material conduit device relative to the manifold insert is resisted.
17. The injection molding apparatus as claimed in claim 1 ;
further comprising:
a plurality of molten material conduit device fasteners;
wherein:
the molten material conduit device includes a plurality of fastener receiving openings disposed within the base flange at spaced apart intervals about the discharge opening;
the manifold insert includes a plurality of receiving openings disposed at spaced apart intervals about the molten material receiver;
disposition of the molten material conduit device on the manifold insert is such that the molten material conduit device fastener receiving openings are disposed in alignment with the fastener receiving openings disposed in the manifold insert; and
engagement of a respective one of the plurality of molten material conduit device fasteners within a corresponding set of aligned molten material conduit device fastener receiving opening and manifold insert fastener receiving openings is with effect that the molten material conduit device is secured to the manifold insert such that displacement of the molten material conduit device relative to the manifold insert is resisted.
18. The injection molding apparatus as claimed in claim 17 ;
wherein:
the engagement of the plurality of molten material conduit device fasteners within the corresponding sets of aligned molten material conduit device fastener receiving opening and manifold insert fastener receiving openings is with effect that a force is applied to the base flange of the molten material conduit device via each of the plurality of molten material conduit device fasteners.
19. (canceled)
20. (canceled)
21. The injection molding apparatus as claimed in claim 1 ;
further comprising:
a locating ring mounted to the back plate, the locating ring having an opening for receiving the inlet end of the molten material conduit device; and
the manifold, the molten material conduit device, the back plate and the locating ring are cooperatively configured such that:
the inlet end is disposed within the opening defined by the locating ring; and
disposition of the inlet end within the opening defined by the locating ring is with effect that:
the inlet opening is located relative to the back plate and configured for engaging the injection machine nozzle;
displacement of the molten material conduit device relative to the back plate is resisted in response to interference between the inlet end of the molten material conduit device and the locating ring; and
a sealed interface is established between the inlet end of the molten material conduit device and the locating ring.
22. An injection molding apparatus for receiving molten material from an injection machine nozzle of an injection molding machine, and delivering the molten material to at least one mold cavity housed within a cavity side of a mold assembly, comprising:
a manifold insert defining a molten material receiver and at least one passageway;
a manifold plate configured for receiving the manifold insert;
a molten material conduit device having an inlet opening for receiving the molten material from the injection machine nozzle, a discharge opening for transmitting the molten material to the molten material receiver, and a molten material conduit extending therebetween; and
a back plate having a molten material conduit device engaging flange defining a molten material conduit device receiving opening, the back plate configured for disposition on the manifold plate and for cooperating with the injection machine nozzle;
wherein:
the molten material conduit device includes a base flange extending outwardly from the discharge opening, the base flange defining:
a manifold insert sealed interface effector; and
an aligner;
and
the manifold insert, the manifold plate, the molten material conduit device and the back plate are cooperatively configured such that:
the manifold insert sealed interface effector is disposed in abutting contact with the manifold insert such that the discharge opening is disposed in communication with the molten material receiver;
the back plate is disposed on the manifold plate such that the molten material conduit device extends through the molten material conduit device-receiving opening such that at least a portion of the base flange is disposed between the manifold insert and the back plate; and
an edge surface of the aligner is disposed in abutting contact the molten material conduit device engaging flange with effect that the discharge opening is disposed in axial alignment with the molten material receiver.
23. The injection molding apparatus as claimed in claim 22 ;
wherein:
the base flange defines a back plate sealed interface effector disposed opposite to the manifold insert sealed interface effector;
and
the manifold insert, the manifold plate, the molten material conduit device and the back plate are cooperatively configured such that:
disposition of the back plate on the manifold plate is with effect that:
a first sealed interface is established between the manifold insert sealed interface effector and the manifold insert; and
a second sealed interface is established between the back plate-sealed interface effector and the back plate.
24. The injection molding apparatus as claimed in claim 22 ;
wherein:
disposition of the back plate on the manifold plate is with effect that:
displacement of the molten material conduit device relative to the manifold insert, such that the discharge opening becomes misaligned relative to the molten material receiver, is resisted in response to interference between the aligner and the molten material conduit device engaging flange.
25. The injection molding apparatus as claimed in claim 22 ;
wherein:
disposition of the back plate on the manifold plate is with effect that:
rotation of the molten material conduit device about an axis that extends normal to a central longitudinal axis of the molten material conduit device, such that the discharge opening becomes misaligned relative to the molten material receiver, is resisted in response to interference between the aligner and the molten material conduit device engaging flange.
26. The injection molding apparatus as claimed in claim 23 ;
wherein:
the molten material conduit device includes a relief passage extending through the base flange from the manifold insert sealed interface effector to a second side of the base flange that is opposite to the manifold insert sealed interface effector; and
the manifold insert, the manifold plate, the molten material conduit device and the back plate are cooperatively configured such that:
while the injection molding machine is disposed in a closed position such that the injection molding apparatus is in communication with the at least one mold cavity, and molten material is delivered to the molten material-receiver from the injection machine nozzle, via the molten material conduit device, defeating of the first sealed interface such that molten material travels between the molten material sealed interface effector and the manifold insert is with effect that the molten material is directed away from the manifold insert via the relief passage.
27. The injection molding apparatus as claimed in claim 26 ;
wherein:
the relief passage includes:
a groove disposed in the manifold insert sealed interface effector of the base flange and extending around the discharge opening; and
a plurality of relief openings disposed at spaced apart intervals about the groove and extending through the base flange, each relief opening having a first open end in communication with the groove and a second open end disposed in the second side of the base flange.
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US17/244,613 US20220118664A1 (en) | 2020-10-20 | 2021-04-29 | Injection molding apparatus |
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US202063094090P | 2020-10-20 | 2020-10-20 | |
US17/244,613 US20220118664A1 (en) | 2020-10-20 | 2021-04-29 | Injection molding apparatus |
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US20220118664A1 true US20220118664A1 (en) | 2022-04-21 |
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US17/244,613 Pending US20220118664A1 (en) | 2020-10-20 | 2021-04-29 | Injection molding apparatus |
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